Material flow modifier and apparatus comprising same

ABSTRACT

Material flow modifiers as disclosed herein overcome drawbacks associated with known adverse flow conditions (e.g., surface erosion, head losses, particulate drop-out, and the like) that arise from flow of certain types of materials (e.g., fluids, slurries, particulates, flowable aggregate, and the like) through a material flow conduit. Such material flow modifiers provide for flow of flowable material within a flow passage of a material flow conduit (e.g., a portion of a pipeline, tubing or the like) to have a rotational flow profile. Advantageously, the rotational flow profile centralizes flow toward the central portion of the flow passage, thereby reducing magnitude of laminar flow to overcome the aforementioned adverse flow conditions.

FIELD OF THE DISCLOSURE

The disclosures made herein relate generally to structural devices usedfor transmission of flowable materials and, more particularly, todevices used for enhancing flow attributes of material within a materialflow conduit such as a pipeline or a tubular flow member.

BACKGROUND

The need to flow materials (i.e., flowable material) through a materialflow conduit is well known. Examples of such materials include, but arenot limited to, fluids, slurries, particulates, particulate-filledfluid, flowable aggregate, and the like. Examples of such material flowconduit include, but are not limited to, pipes, pipelines, conduits,tubular flow members, and the like.

As shown in FIG. 1, conventional flow of flowable material 5 within aflow passage 10 of a material flow conduit 15 has a flow profilecharacterized by laminar flow effect (i.e., laminar flow 20). Theparabolic flow profile is a result of the laminar boundary layer alongthe surface of the material flow conduit 15 defining the flow passage10. Flowable material at the surface of the flow passage 10 exhibitsconsiderable friction and zero flow velocity, thereby reducing velocityof the flowable material even at a considerable distance from thesurface of the flow passage 10. In association with this reducedvelocity, the laminar flow effect (e.g., friction at the surface of thematerial flow conduit) is known to increase head loss and heating of theflowable material.

There are various well-known flow considerations that arise whenflowable material and, particularly abrasive flowable material, flowsthrough a material flow conduit such as a pipeline. One suchconsideration is erosion (i.e., wearing) of the material flow conduit.Transport and pumping flowable material comprising abrasive contents,such as coal and sand slurries, wet sand, gravel and the like can causeespecially high costs associated with component wear due to interactionbetween the flowable material and the surface defining the passagethrough which such material flows. Additionally, uneven erosion inpiping systems, especially elbow fittings, is well known to lead tofitting failure or early fitting replacement, either of which is costlyin material, manpower and downtime.

When fluids or flowable materials pass through an elbow fitting, thechange in direction creates turbulent conditions, flow separation andvortex shedding along the pipe wall at the inside of the bend. Thischange in direction may also create standing eddies causing backflowconditions at points along the elbow fitting pipe walls. Theseconditions generally cause the elbow fitting pipe wall along the outsideof the bend to erode substantially faster than the pipe wall along theinside of the bend because the flowable material impinges directlyagainst the wall along the outside of the bend as it enters the fittingand changes direction. Additionally, due to centrifugal force, heaviersolids and particulates are generally thrown to the outside wall as theflowable material changes direction and tend to continually scour theouter wall.

A similar uneven erosion effect is often experienced in straight piperuns. For example, the concentration of particulates of a flowablematerial will increase in the lower region of the fluid in long straightruns (i.e., particulate dropping out of suspension), making the bottomportion of the fluid stream more abrasive or prone to materialdeposition and/or aggregation than the upper portion. Such materialdeposition and/or aggregation can alter fluid flow conditions (e.g.,velocity, temperature, pressure and the like) and can alter the materialcomposition of the flowable material (e.g., less downstreamconcentration of particular than required or intended). Additionally, inlarge diameter piping systems, the weight of the flowable material isborne by the lower pipe wall portion thereby causing higher erosionrates.

Another well-known flow consideration that arises is head loss due toturbulence and flow separation in an elbow fitting. Higher pumpingpressures can be utilized for mitigating this head loss resulting fromsuch head losses. However, higher pumping pressures are generallyimplemented at the expense of higher energy consumption and associatedcost. Additionally, implementation of higher pumping pressures oftencreates vibration and heating problems in the piping system.

Long radius elbow fittings and pipe sections can reduce these adverseflow considerations. However, long radius fittings require a great dealof space relative to standard (i.e., short) radius fittings.Additionally, long radius fittings still suffer accelerated erosionrates along the pipe wall along the outside of the bend becausecentrifugal force still causes heavier, more abrasive flowable materialsto be thrown to the outer wall, and they are continually scoured byon-going flow of such flowable material.

Therefore, a device that overcomes one or more drawbacks associated withknown flow considerations that arise from flow of abrasive and/orparticulate-filled material flowing through a material flow conduitwould be beneficial, desirable and useful.

SUMMARY OF THE DISCLOSURE

Embodiments of the disclosures made herein are directed to a device thatovercomes one or more drawbacks associated with known adverse flowconditions in pipe structures. These drawbacks include, for example,surface erosion, head losses, fluid cavitation, heating, particulatesdropping out of suspension, material composition changes, and the like.These adverse flow conditions are known to arise from flow of certaintypes of materials (e.g., fluids, slurries, particulates,particulate-filled fluid, flowable aggregate, and the like) through amaterial flow conduit. A material flow modifier in accordance with oneor more embodiments of the disclosures made herein enables flow offlowable material within a flow passage of a material flow conduit(e.g., a portion of a pipeline, tubing or the like) to have a rotationalflow profile—i.e., sometimes referred to as cyclonic or vortex flow.Advantageously, such a rotational flow profile centralizes flow toward acentral portion of the flow passage, thereby reducing the magnitude oflaminar flow. Such rotational flow profile provides a variety of otheradvantages as compared to a parabolic flow profile resulting fromlaminar flow (e.g., increased flow rate, reduce inner pipeline wear,more uniform inner pipe wear, reduction in energy consumption, reducedor eliminated slugging, maintaining particulates in fluid suspension andthe like).

Advantageously, material flow modifiers in accordance with one or moreembodiments of the disclosures made herein are especially efficient andeffective at keeping particles suspended with a fluid, thereby aiding inkeeping the particle-filled material continuous/free flowing andproviding unrestricted material flow passages. Moreover, in materialflow systems having existing build-up of materials in the bottom and/orother portion of the fluid flow conduit, material flow modifiers inaccordance with one or more embodiments made herein create a rotationalflow profile that enhances the flow of material through fluid flowconduit having surface obstructions (e.g., material deposits and/orparticles having fallen out of suspension), and in some instances, suchrotational flow profile can serve to remove all or a portion of suchexisting build-up of materials.

In one or more embodiment, a material flow modifier comprises aninterior tubular body and a plurality of helical passage bodies. Theinterior tubular body has an interior surface and an exterior surface.The interior surface defines a central passage of the interior tubularbody. The central passage of the interior tubular body has a generallyround cross-sectional shape. The central passage of the interior tubularbody expands along a length thereof from a smallest cross-sectional areaat or near (i.e., adjacent) an inlet of the interior tubular body to alargest cross-sectional area at or near an outlet of the interiortubular body. The plurality of helical passage bodies each surround andextend along a length of the interior tubular body. Each of the helicalpassage bodies defines a helical passage therein extending along alength thereof. The helical passage of each of the helical passagebodies has an inlet at or near to the inlet of the interior tubular bodyand an outlet at or near to the outlet of the interior tubular body.Each helical passage tapers along a respective length thereof from alargest cross-sectional area at or near the inlet thereof to a smallestcross-sectional area at or near the outlet thereof.

In one or more embodiments, a material flow modifier comprises anexterior tubular body, an interior tubular body and a plurality of helixvanes. The exterior tubular body has a central passage extendingtherethrough and defining a centerline longitudinal axis thereof. Thecentral passage of the exterior tubular body has a generally roundcross-sectional shape. The interior tubular body is within the centralpassage of the exterior tubular body. A central passage of the interiortubular body has a generally round cross-sectional shape. A centerlinelongitudinal axis of the central passage of the interior tubular bodyextends colinearly with the centerline longitudinal axis of the exteriortubular body. The central passage of the interior tubular body expandsalong a length thereof from a smallest cross-sectional area at or near(i.e., adjacent) a first end portion of the exterior tubular body to alargest cross-sectional area at or near a second end portion of theexterior tubular body. Each of the helix vanes extends between aninterior surface of the exterior tubular body and an exterior surface ofthe interior tubular body thereby defining a plurality of helicalpassages between the exterior tubular body, the interior tubular bodyand respective adjacent ones of the helix vanes. Each of the helicalpassages tapers along a respective length thereof from a largestcross-sectional area at or near the first end portion of the exteriortubular body to a smallest cross-sectional area at or near the secondend portion of the exterior tubular body.

In one or more embodiments, a material flow modifying apparatuscomprises an inlet flow body, a material flow modifier having a firstend portion thereof attached to the inlet flow body and an outlet flowbody attached to a second end portion of the material flow modifier. Thematerial flow modifier comprises an interior tubular body and aplurality of helical passage bodies surrounding and extending along alength of the interior tubular body. The interior tubular body has aninterior surface and an exterior surface. The interior surface defines acentral passage of the interior tubular body. The central passage of theinterior tubular body has a generally round cross-sectional shape andexpands along a length thereof from a smallest cross-sectional area ator near an inlet of the interior tubular body to a largestcross-sectional area at or near an outlet of the interior tubular body.Each of the helical passage bodies defines a helical passage thereinextending along a length thereof. The helical passage of each of thehelical passage bodies has an inlet adjacent to the inlet of theinterior tubular body and an outlet adjacent to the outlet of theinterior tubular body. Each helical passage tapers along a respectivelength thereof from a largest cross-sectional area at or near the inletthereof to a smallest cross-sectional area at or near the outletthereof. The outlet of the interior tubular body and the outlet of eachof the helical passages are in fluid communication with the centralpassage of the outlet flow body.

In one or more embodiments, a portion of the interior tubular body is awall of each of the helical passage bodies.

In one or more embodiments, the cross-sectional area of the centralpassage of the interior tubular body expands linearly along the lengththereof between the inlet and outlets of the interior tubular body.

In one or more embodiments, the inlet of each of the helical passagesand the inlet of the central passage of the interior tubular body atleast partially lie in a common plane.

In one or more embodiments, the outlet of each of the helical passagesand the outlet of the central passage of the interior tubular body atleast partially lie in a common plane.

In one or more embodiments, an outer wall of each of the helical passagebodies is cylindrical.

In one or more embodiments, the cylindrical outer wall of all of thehelical passage bodies have a uniform wall thickness along a lengththereof.

In one or more embodiments, a centerline longitudinal axis of thecentral passage of the interior tubular body extends colinearly with acenterline longitudinal axis of the cylindrical outer wall of all of thehelical passage bodies.

In one or more embodiments, the helical passage bodies jointly define anexterior wall and/or surface of the material flow modifier.

In one or more embodiments, each of the helical passage bodies has anouter wall, an inner wall and opposing sides walls.

In one or more embodiments, the inner wall of each of the helicalpassage bodies is a respective portion of a wall defining the interiortubular body.

In one or more embodiments, each of the opposing walls is a helix vaneextending between the outer and inner walls.

In one or more embodiments, the inlet flow body, the interior tubularbody and the outlet flow body each have a central passage defining arespective centerline longitudinal axis and each of the centerlinelongitudinal axes extends colinear with each other one of the centerlinelongitudinal axes.

In one or more embodiments, the inlet flow body and the outlet flow bodyeach have an upstream end portion and a downstream end portion; thefirst end portion of the material flow modifier is attached to thedownstream end portion of inlet flow body; the second end portion of thematerial flow modifier is attached to the upstream end portion of outletflow body; a cross-sectional area of the central passage in thedownstream portion of the inlet flow body is greater than across-sectional area of the central passage in the upstream portion ofthe inlet flow body; and a cross-sectional area of the central passagein the upstream portion of the outlet flow body is greater than across-sectional area of the central passage in the downstream portion ofthe outlet flow body.

These and other objects, embodiments, advantages and/or distinctions ofthe disclosures made herein will become readily apparent upon furtherreview of the following specification, associated drawings and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application contains at least one drawing executed in color. Copiesof this patent or patent application publication with color drawing(s)will be provided by the Office upon request and payment of the necessaryfee

FIG. 1 is a diagrammatic view showing laminar flow effect within amaterial flow conduit.

FIG. 2 is a diagrammatic view showing conversion from a laminar floweffect to rotation flow effect by a material flow modifier configured inaccordance with one or more embodiments of the disclosures made herein.

FIG. 3 is a first perspective view of material flow modifier configuredin accordance with one or more embodiments of the disclosures madeherein.

FIG. 4 is a second perspective view of material flow modifier shown inFIG. 3.

FIG. 5 is a cross-sectional view taken along the line 5-5 in FIG. 4.

FIG. 6 is an inlet end view of the material flow modifier shown in FIG.3.

FIG. 7 is an inlet end view of the material flow modifier shown in FIG.3.

FIG. 8 is a cross-sectional view showing a material flow modifyingapparatus configured in accordance with one or more embodiments of thedisclosures made herein.

FIG. 9 is a color diagrammatic view showing relative fluid flowvelocities for a material flow modifier configured in accordance withone or more embodiments of the disclosures made herein.

DETAILED DESCRIPTION

Embodiments of the disclosures made herein are directed to material flowmodifiers. Such material flow modifiers are preferably passive devicesthat have no parts that actively move during operation. Rather, thesematerial flow modifiers preferably operate on the existing flow velocityof a pumping system within fluid flow apparatus comprising the pumpingsystem. Accordingly, when there is flow velocity in the fluid flowapparatus, a material flow modifier in accordance with the disclosuresmade herein is preferably always operational. Utilization of a materialflow modifier as disclosed herein can include inserting a material flowmodifier inline within an existing pipe structure of a fluid flowapparatus or configuring the material flow modifier as a length of fluidflow conduit. Material flow modifiers is sized to be compatible with(e.g., match) flow rates of the existing pipe structure.

As discussed above in reference to FIG. 1, conventional flow of flowablematerial 5 within the flow passage 10 of the material flow conduit 15has a flow profile characterized by laminar flow effect (i.e., laminarflow 20). However, material flow modifiers in accordance with thedisclosures made herein (e.g., the material flow modifier 1 shown inFIG. 2) are advantageously configured in a manner that causesconventional flow to be transformed from a flow profile characterized bylaminar flow effect to a flow profile being characterized by rotationalflow effect 25—i.e., rotational flow sometimes referred to as cyclonicor vortex flow. The rotational flow effect is the result of rotationalmovement of the flowable material 5 about the longitudinal axis L1 ofthe material flow conduit 15 as generated by the material flow modifier1.

As a person of ordinary skill in the art will understand, rotationalflow provides greater average flow velocity and volumetric flow thanlaminar flow for a given material flow conduit (e.g., as depicted inFIGS. 1 and 2). Additionally, rotational flow mitigates adverseinteraction between the surface of the material flow conduit and theflowable material. These advantageous aspects of rotational flow arisefrom the rotational flow profile accelerating and centralizing flow ofthe flowable material toward the central portion of the flow passage 10,thereby mitigating associated adverse flow conditions (e.g., particulatefalling out of suspension) and amplifying flow magnitude. In thisregard, material flow modifiers in accordance with the disclosures madeherein beneficially provide rotational flow that transports flowablematerials more effectively and efficiently than in conventional pipingsystems exhibiting laminar flow.

Referring now to FIGS. 3-7, specific aspects of a material flow modifierin accordance with one or more embodiments of the disclosures madeherein (i.e., material flow modifier 100) are discussed. The materialflow modifier 100 includes an exterior tubular body 102, an interiortubular body 104 and a plurality of helix vanes 106. The exteriortubular body 102 has a central passage 108 extending therethrough anddefining a centerline longitudinal axis L2 of the exterior tubular body102. The central passage 108 of the exterior tubular body 102 preferablyhas a generally round cross-sectional shape.

The interior tubular body 104 is within the central passage 108 of theexterior tubular body 102. A central passage 110 of the interior tubularbody 104, defined by an interior surface 111 of the interior tubularbody 104, preferably has a generally round cross-sectional shape. Acenterline longitudinal axis L3 of the central passage 110 of theinterior tubular body 104 preferably extends colinearly with thecenterline longitudinal axis L2 of the exterior tubular body 102 (e.g.,a cylindrical wall thereof). The central passage 110 of the interiortubular body 104 expands along a length thereof from a smallestcross-sectional area adjacent a first end portion 112 of the exteriortubular body 102 to a largest cross-sectional area adjacent a second endportion 114 of the exterior tubular body 102. Preferably, thecross-sectional area of the central passage 110 of the interior tubularbody 104 expands linearly along a length of the interior tubular body104—i.e., as illustrated in FIG. 4 as a straight-tapered conicalstructure). In the context of the disclosures made herein, adjacentpreferably means at (e.g., at the first end portion) but less preferablyadjacent can also mean near (e.g., near the first end portion). It isdisclosed herein that the cross-sectional area of the central passage110 of the interior tubular body 104 can expand non-linearly along thelength of the interior tubular body 104.

The plurality of helix vanes 106 are within the central passage 108 ofthe exterior tubular body 102. Each of the helix vanes 106 extendsbetween an interior surface 116 of the exterior tubular body 102 and anexterior surface 118 of the interior tubular body 104. In this manner, aplurality of helical passages 120 are defined between the exteriortubular body 102, the interior tubular body 104 and respective adjacentones of the helix vanes 106. More specifically, each of the helicalpassages 120 extends within a respective helical passage body 121 thatsurrounds and extends along a length of the interior tubular body 104.As best shown in FIGS. 6 and 7, each of the helical passage bodies 121has an outer wall (i.e., a respective portion of the exterior tubularbody 102), an inner wall (i.e., a respective portion of the interiortubular body 104) and opposing sides walls (i.e., each defined by arespective one of the helix vanes 106). As best shown in FIG. 3, theinner walls of each helical passage body 121 can be angled off by up toabout 12 degrees. This profile aids in directing fluid flow into eachhelical passage body 121 with minimum resistance. Additionally, thisprofile opposes any back wall forces in the chambers and adds strengthto the material flow modifier.

The helical passage 120 of each of the helical passage bodies 121 has aninlet 122 adjacent to an inlet 124 of the central passage 110 of theinterior tubular body and an outlet 126 adjacent to an outlet 128 of thecentral passage 110 of the interior tubular body 104. Preferably, theplurality of helical passage bodies 121, the exterior tubular body 102and the interior tubular body 104 are all identically or approximatelythe same length to enable the inlet 122 of each of the helical passages120 and the inlet 124 of the central passage 110 of the interior tubularbody 104 entirely or partially lie in a common plane and to enable theoutlet 126 of each of the helical passages 120 and the outlet 128 of thecentral passage 110 of the interior tubular body 104 entirely orpartially lie in a common plane. However, it is contemplated herein thatthe inlet 122 of each of the helical passages 120 and the inlet 124 ofthe central passage 110 of the interior tubular body 104 can entirely orpartially lie in spaced-apart planes and that the outlet 126 of each ofthe helical passages 120 and the outlet 128 of the central passage 110of the interior tubular body 104 can entirely or partially lie inspaced-apart planes.

Each of the helical passages 120 tapers along a respective lengththereof from a largest cross-sectional area adjacent the first endportion 112 of the exterior tubular body 102 to a smallestcross-sectional area adjacent the second end portion 114 of the exteriortubular body 102. Preferably, such taper of the helical passages 120arises as a result of the exterior tubular body 102 being cylindricaland having a generally uniform wall thickness in combination with theinterior tubular body 104 having a generally uniform wall thickness andhaving a cross-sectional area that expands along the length of theinterior tubular body 104 from adjacent the first end portion 112 of theexterior tubular body 102 to adjacent the second end portion 114 of theexterior tubular body 102. Optionally, for a given uniform outsidediameter of the exterior tubular body 102 and a given expansion of thecross-sectional area of the central passage of the interior tubular body104, it is disclosed herein that such taper of the helical passages 120can arise entirely or at least partially as a result of one or morestructural considerations of the following: the thickness of theexterior tubular body 102 tapering from a first thickness adjacent tothe first end portion 112 of the exterior tubular body 102 to anincreased thickness adjacent to the second end portion 114 of theexterior body 102 and the thickness of the interior tubular body 104tapering from a first thickness adjacent to the first end portion 112 ofthe exterior tubular body 102 to an increased thickness adjacent to thesecond end portion 114 of the exterior body 102.

Referring now to FIG. 8, a material flow modifying apparatus inaccordance with one or more embodiments of the disclosures made herein(i.e., material flow modifying apparatus 200) is shown. The materialflow modifying apparatus 200 comprises an inlet flow body 205, amaterial flow modifier unit 210 and an outlet flow body 215. Thematerial flow modifier unit 210 has a first end portion 220 attached tothe inlet flow body 205 and has a second end portion 225 attached to theoutlet flow body 215. The inlet flow body 205, the material flowmodifier unit 210 and the outlet flow body 215 are in fluidcommunication with each other. In preferred embodiments, the inlet flowbody 205, the housing 210 and the outlet flow body 215 each have acentral passage with a respective centerline longitudinal axis L4-L6 andeach of the centerline longitudinal axes L4-L6 extends colinearly witheach other one of the centerline longitudinal axes L4-L6.

The material flow modifier unit 210 includes a material flow modifier230 and a housing 235. The material flow modifier 230 is a material flowmodifier in accordance with one or more embodiments of the disclosuresmade herein. To this end, the material flow modifier 230 can have anoverall construction and functionality similar to that the material flowmodifier 100 discussed above in reference to FIGS. 3-7.

The material flow modifier 230 can be engaged within a central passage240 (i.e., an interior space) of the housing 235. Engagement of thematerial flow modifier 230 within the central passage 240 of the housing235 enables the housing to carry all or a portion of the structural load(e.g., radial stress and strain) arising from the flow of pressurizedfluid though the material flow modifier unit 210. As shown, in one ormore embodiments, the housing 230 is of a cylindrical construction(e.g., a length of pipe or tubing). In other embodiments, the housing230 can be of a non-tubular cylindrical construction—e.g., a housingwith a non-round central passage where one or more mating surfaces ofthe material flow modifier 230 engage one or more surfaces of thenon-round central passage to limit unrestricted rotational movementtherebetween. One or more outside dimensions of the material flowmodifier 230 (e.g., an outside dimension D) can be configured forenabling the material flow modifier 230 to be positioned within thecentral passage 240 of the housing 235 in a manner that limits radialtranslation, pivotal translation or a combination thereof.

The material flow modifier 230 can include a flange 245 at the first endportion 220 to engage a mating surface of the housing 235 (e.g., an endface 250 thereof) for limiting unrestricted axial movement therebetween.In preferred embodiments, a height H of the flange 245 is approximatelythe same as a height of the mating surface of the housing 235 (e.g.,wall thickness T). In one or more other embodiments, a securement devicecan be used for limiting unrestricted axial and/or rotational movementbetween the material flow modifier 230 and the housing 235—e.g., awelded interface, an adhesive interface, a circular-clip in a groove, athreaded fastener engaged in a threaded hole, a threaded fastenerextending through an aperture and engaged in a threaded hole, and thelike.

It is disclosed herein that, in one or more embodiments, the housing 235of the material flow modifier unit 210 can be omitted, whereby the inletflow body 205 and the outlet flow body 215 can be attached directly toopposing end portions of the material flow modifier 230. Such omissionof the housing 235 can require a specific configuration of certainstructural aspects of the material flow modifier 230 to be taken intoconsideration. One such consideration is a thickness of an outer wall232A of the material flow modifier 230 being of a suitable strength forcontaining pressure within the material flow modifier 230. Another suchconsideration is removing the flange 245 to eliminate anyadverse/undesirable interference between the flange 245 and the inletflow body 205.

In one or more embodiments, as shown, the inlet flow body 205 and theoutlet flow body 215 each have an upstream end portion 205A, 215A,respectively, and a downstream end portion 205B, 215B, respectively. Thefirst end portion 220 of the material flow modifier 230 is attached tothe downstream end portion 205B of inlet flow body 205 and the secondend portion 225 of the material flow modifier 230 is attached to theupstream end portion 215A of outlet flow body 215. A cross-sectionalarea of the central passage in the downstream portion 205B of the inletflow body 205 is greater than a cross-sectional area of the centralpassage in the upstream portion 205A of the inlet flow body 205. Across-sectional area of the central passage in the upstream portion 215Aof the outlet flow body 215 is greater than a cross-sectional area ofthe central passage in the downstream portion 215B of the outlet flowbody 215. In view of the total material flow areas of the material flowmodifier 230, this cross sectional area profile of the inlet flow body205 advantageously enables pressure reduction at the inlet of the helixpassages and central aperture of the material flow modifier 230, enablesflow volume to be maintained through the helix passages and centralaperture of the material flow modifier 230, and enables increases flowvelocity through the material flow modifier 230.

Turning now to a method of making a material flow modifier apparatus inaccordance with the disclosures made herein, in one or more embodiments,a material flow modifier in accordance with the disclosures made herein(e.g., the material flow modifier 230 of FIG. 8) is provided. Next, thematerial flow modifier is inserted into a central passage of a materialflow modifier housing (i.e., the housing 235 of FIG. 8) and is fixedlyengaged therewith to limit at least one of unrestricted axial movement,radial movement, pivotal movement and axial movement. Next, an inletflow body (i.e., the inlet flow body 205 of FIG. 8) is attached to afirst end portion of the housing and an outlet flow body (i.e., theoutlet flow body 215 of FIG. 8) is attached to a second end portion ofthe housing. The inlet flow body and the outlet flow body can each besecured to the housing by means such as, for example, mechanical means(e.g., a flange or shoulder on the material flow modifier, or the like),thermal means (e.g., heat staking, laser joining or the like), metaldeposition means (e.g., welding or the like), threaded fastener means(e.g., bolt, screw or the like), adhesive means and/or the like.

In operation, pressurized material flow (e.g., particulate-filled fluid)at the first end portion of a material flow modifier in accordance withone or more embodiments of the disclosures made herein causes acontinuous rotational (i.e., vortex) flow of such fluid flow at thedownstream side (i.e., outlet) of the material flow modifier. At theinlet region of the material flow modifier, material flow is restrictedthrough the central passage of the interior tubular body. This materialflow restriction forces a portion of the material flow into the helicalpassages and a remaining portion enters the interior tubular body. Theportion of the material flow passing through the helical passageswhereby a rotational flow around the centerline longitudinal axis of theinterior tubular body is generated. As the portion of the material flowpasses through the central passage of the interior tubular body, itbecomes less restricted thereby allowing the material flow exiting thehelical passages to control and transform the material flow exiting thecentral passage of the interior tubular body. At the outlet of thehelical passages, this rotational material flow from the helicalpassages merges with material flow from the central passage of theinterior tubular body. Merging of these material streams creates aharmonious rotational flow in which pipeline pressure is decreased so asto create pipeline fluid acceleration, to evenly distribute suspendedparticles into the material flow modifier and to keep suspendedparticles from dropping out of suspension to cause restricted materialflow downstream of the material flow modifier.

Because each stream of material flowing from within the plurality ofmaterial flow passages are proportional, the greatest rotational spin isachieved downstream from the material flow modifier. Surface and fluidfriction causes the rotational flow to decrease over time and distance(i.e., to decay), which can be offset by utilization of multiplein-line, spaced-apart material flow modifiers. Additionally, a skilledperson will understand that flowable material being forcibly urgedthrough the helical passages, which are all tapered, creates a venturieffect. This venturi effect decreases pressure at the outlet of thematerial flow modifier. With the pressure decreased, fluid accelerationis created. With less pressure in the material flow system, a pump ofthe system can operate more efficiently (e.g., using less energy).Moreover, suspended particles in the flowable material will more readilyremain in suspension, thereby reducing blockages in material flowconduits (e.g., pipes, pipelines and tubes).

In a material flow modifier in accordance with one or more embodimentsof the disclosures made herein, the greatest fluid acceleration is atthe point where material flow exiting the helical passages to controland transform the material flow exiting the central passage of theinterior tubular body. The balance of this material flow motion is asiphoning action and a vector at the inlet of the material flowmodifier. As illustrated in FIG. 9, the material's velocity at the inletpoint in the central passage of the interior tubular body is momentarilyincreased, but is fully diminished at about the half-way point of theinterior tubular body. This is at the reference point where the velocitybegins substantial increase within the helical passages and sustainsthis velocity increase to the exit of the helical passages. Thisreference point is variable and floats off center as pumping flows areincreased or lowered. Moreover the structural configuration of thematerial flow modifier results in a draft over its entire inlet areathereby generating a siphoning effect upstream of the material flowmodifier. This upstream siphoning effect creates a vector at the inletof the material flow modifier starting the first step in changing theflow from parabolic to rotational.

Material flow modifiers in accordance with the disclosures made hereinhave a plurality of flow modification variables that can influence themanner in which they modify fluid flow. These variables include, but arenot limited to, number of helical passages, total angular wrap ofhelical passages along the length of the material flow modifier, ratioof total flow inlet area of the helical passages to the total flow inletarea (i.e., area of helical passages and interior tubular body), ratioof total flow outlet area of the helical passages to the total flowoutlet area (i.e., area of helical passages and interior tubular body),total flow inlet area, total flow outlet area, spacing of the helicalpassages (e.g., equally spaces vs. unequally spaced), mode ofcross-sectional area transition for the central passage of the interiortubular body (e.g., linearly vs. non-linearly), mode of cross-sectionalarea transition for the helical passages (e.g., linearly vs.non-linearly). To achieve a desired flow modification characteristic,one or more of these flow modification variables can be altered toachieve the desired flow modification.

In one or more embodiments of a material flow modifier in accordancewith the disclosures made herein, the following flow modificationvariables are prescribed: equally-spaced helical passages andpassageways; the total cross-sectional inlet area of all of the helicalpassages is up to 80% of the total inlet area; the total cross-sectionaloutlet area of all of the helical passages is about 20% of the totalinlet area; the cross-sectional area of each helical passage at anygiven axial location of the material flow modifier over its linearlength are all equal; and over the length of the material flow modifier,each helical passage has about a 250-degrees to 290-degree scroll and,preferably, about 270-degrees. A given reduction in helical passagecross-sectional area in combination with a given count of scrollcontributes to determination of a length of a material flow modifier. Inone or more other embodiments, the total cross-sectional inlet area ofall of the helical passages is up to 60% of the total inlet area and thetotal cross-sectional outlet area of all of the helical passages isabout 30% of the total inlet area. In one or more other embodiments, thetotal cross-sectional inlet area of all of the helical passages isbetween 60%-80% of the total inlet area and the total cross-sectionaloutlet area of all of the helical passages is between 20%-30% of thetotal inlet area. In still one or more other embodiments, the totalcross-sectional inlet area of all of the helical passages is between50%-70% of the total inlet area and the total cross-sectional outletarea of all of the helical passages is between 30%-40% of the totalinlet area.

Material flow modifiers in accordance with embodiments of thedisclosures made herein are useful with all types of piping requirementssuch as, for example, chemical, heavy slurry, concrete pumping devices,sewage, and FDA food grade transfer systems. Material flow modifiers inaccordance with embodiments of the disclosures made herein can be of aone-piece construction. Material flow modifiers in accordance withembodiments of the disclosures made herein can be of a multi-piececonstruction. Material flow modifiers in accordance with embodiments ofthe disclosures made herein can be fabricated utilizing various knownand yet to be discovered materials and fabrication techniques. Examplesof useful material classes include, but are not limited to, metallicmaterial (e.g., metal alloys such as stainless steel), concrete (i.e., acement-based material), and polymeric materials (e.g., plastics such asABS or nylon). Examples of useful fabrication techniques include, butare not limited to, casting, forging, welding and the like for metallicmaterials and casting, molding, 3-D printing and the like for polymericmaterials.

Discussed now are various advantageous aspects of material flowmodifiers in accordance with embodiments of the disclosures made herein.One such advantageous aspect is that the incorporation of the helicalpassage bodies and central passage of the interior tubular body, whichprovide for rotational flow. Each of the helical passages uses thekinetic energy (i.e., energy from motion) and the flow's velocity togenerate several stream vanes of material flow (i.e., helical flowstreams) that unite at and beyond the outlet of the material flowmodifier with each other and with the material flow of the centralpassage of the interior tubular body. These material flows can befocused by an outlet flow body of a material flow modifying apparatus.Beneficially, the outlet flow body enhances rotational flow anddistributes an even (i.e., balanced) rotational flow profile about thecenterline of the material flow modifier. Advantageously, inner sidewallconditions of material flow conduit (e.g., pipeline) downstream of amaterial flow modifier has a negligible effect on the rotational flow.Although there is a great deal of energy loss from a fluid going throughcertain disruptive material flow attributes of material flow conduits(e.g., a valve, fitting, or turbulence created going from passing fluidfrom one pipe size to another), rotational flow mitigates energy lossfrom these disruptive material flow attributes of material flow conduitsby providing for concentration of material flow along the centerline ofmaterial flow conduit downstream of the material flow modifier therebyreducing sidewall drag and flow resistance.

Another advantageous aspect of material flow modifiers in accordancewith one or more embodiments of the disclosures made herein is providingfor “back-flow restriction”. With such a back-flow restriction, if thereis ever a back-flow surge in a system comprising one or more materialflow modifiers in accordance with one or more embodiments of thedisclosures made herein, the material flow modifier serves to reduce theback-flow (i.e., flow in the upstream direction) as compared to thematerial flow modifier being absent. Such soft reverse flow beneficiallydoes not fully inhibit back-flow, which would create a shock wave (i.e.,often referred to as a “water-hammer”) that is harmful to the structuresof the material flow conduit, and to the pumping devices. In a gravityflow system, this soft reverse flow is especially beneficial where tidewater or flooding could reverse flow in a conventional pipeline system.More specifically, in a reverse flow scenario, flowable material entersthe helical passages from the flow mixer and then dissipates into the‘funnel’ of the interior tubular body, which creates a controlled flowblockage (i.e., controlled funnel flow). In this regard, soft reverseflow is enabled by inclusion of material flow passages defined betweenthe exterior tubular body and the interior tubular body and by thefunnel-shape of the interior tubular body itself.

Although the invention has been described with reference to severalexemplary embodiments, it is understood that the words that have beenused are words of description and illustration, rather than words oflimitation. Changes may be made within the purview of the appendedclaims, as presently stated and as amended, without departing from thescope and spirit of the invention in all its aspects. Although theinvention has been described with reference to particular means,materials and embodiments, the invention is not intended to be limitedto the particulars disclosed; rather, the invention extends to allfunctionally equivalent technologies, structures, methods and uses suchas are within the scope of the appended claims.

What is claimed is:
 1. A material flow modifier, comprising: an interiortubular body having an interior surface and an exterior surface, whereinthe interior surface defines a central passage of the interior tubularbody, wherein the central passage of the interior tubular body has agenerally round cross-sectional shape and wherein the central passage ofthe interior tubular body expands along a length thereof from a smallestcross-sectional area adjacent an inlet of the interior tubular body to alargest cross-sectional area adjacent an outlet of the interior tubularbody; and a plurality of helical passage bodies surrounding andextending along a length of the interior tubular body, wherein each ofthe helical passage bodies has opposing side walls, an outer wall and aninner wall jointly defining a helical passage therebetween, wherein eachof the helical passages extend along a length of the respective one ofthe helical passage bodies, wherein the helical passage of each of thehelical passage bodies has an inlet adjacent to the inlet of theinterior tubular body and an outlet at a terminal end thereof adjacentto an outlet of the interior tubular body, wherein the cross-sectionalarea of the outlet of each helical passage is bound by the opposing sidewalls thereof, the outer wall thereof and the inner wall thereof tothereby allow material flow through the outlet of the helical passage tomerge with material flow from the outlet of the interior tubular bodyand wherein each helical passage tapers along a respective lengththereof from a largest cross-sectional area adjacent the inlet thereofto a smallest cross-sectional area adjacent the outlet thereof.
 2. Thematerial flow modifier of claim 1 wherein a portion of the interiortubular body is a wall of each of the helical passage bodies.
 3. Thematerial flow modifier of claim 2 wherein the cross-sectional area ofthe central passage of the interior tubular body expands linearly alongthe length thereof between the inlet and outlets of the interior tubularbody.
 4. The material flow modifier of claim 3 wherein: an upstream endface of each of the helical passage bodies and an upstream end face ofthe interior tubular body all lie in a common plane; and a downstreamend face of each of the helical passage bodies and a downstream end faceof the interior tubular body all lie in a common plane.
 5. The materialflow modifier of claim 1 wherein the cross-sectional area of the centralpassage of the interior tubular body expands linearly along the lengththereof between the inlet and outlets of the interior tubular body. 6.The material flow modifier of claim 1 wherein: an upstream end face ofeach of the helical passage bodies and an upstream end face of theinterior tubular body all lie in a common plane; and a downstream endface of each of the helical passage bodies and a downstream end face ofthe interior tubular body all lie in a common plane.
 7. The materialflow modifier of claim 1 wherein: the outer wall of each of the helicalpassage bodies is cylindrical; said cylindrical outer wall of all of thehelical passage bodies have a uniform wall thickness along a lengththereof; and a centerline longitudinal axis of the central passage ofthe interior tubular body extends colinearly with a centerlinelongitudinal axis of said cylindrical outer wall of all of the helicalpassage bodies.
 8. The material flow modifier of claim 1 wherein: theinner wall of each of the helical passage bodies is a respective portionof a wall defining the interior tubular body; and each of said opposingwalls is a helix vane.
 9. The material flow modifier of claim 8 wherein:the outer wall of each of the helical passage bodies is cylindrical;said cylindrical outer wall of all of the helical passage bodies have auniform wall thickness along a length thereof; and a centerlinelongitudinal axis of the central passage of the interior tubular bodyextends colinearly with a centerline longitudinal axis of saidcylindrical outer wall of all of the helical passage bodies.
 10. Thematerial flow modifier of claim 9 wherein the cross-sectional area ofthe central passage of the interior tubular body expands linearly alongthe length thereof between the inlet and outlets of the interior tubularbody.
 11. The material flow modifier of claim 9 wherein: an upstream endface of each of the helical passage bodies and an upstream end face ofthe interior tubular body all lie in a common plane; and a downstreamend face of each of the helical passage bodies and a downstream end faceof the interior tubular body all lie in a common plane.
 12. The materialflow modifier of claim 11 wherein the cross-sectional area of thecentral passage of the interior tubular body expands linearly along thelength thereof between the inlet and outlets of the interior tubularbody.
 13. The material flow modifier of claim 1 wherein: thecross-sectional area of the central passage of the interior tubular bodyexpands linearly along the length thereof between the inlet and outletsof the interior tubular body; the inner wall of each of the helicalpassage bodies is a respective portion of a wall defining the interiortubular body; and each of said opposing walls is a helix vane.
 14. Thematerial flow modifier of claim 13 wherein: an upstream end face of eachof the helical passage bodies and an upstream end face of the interiortubular body all lie in a common plane; and a downstream end face ofeach of the helical passage bodies and a downstream end face of theinterior tubular body all lie in a common plane.
 15. A material flowmodifier, comprising: an exterior tubular body having a central passageextending therethrough and defining a centerline longitudinal axisthereof and wherein the central passage of the exterior tubular body hasa generally round cross-sectional shape; an interior tubular body withinthe central passage of the exterior tubular body, wherein a centralpassage of the interior tubular body has a generally roundcross-sectional shape, wherein the central passage of the interiortubular body has an inlet adjacent an upstream end portion of theexterior tubular body and an outlet adjacent a downstream end portion ofthe exterior tubular body, wherein a centerline longitudinal axis of thecentral passage of the interior tubular body extends colinearly with thecenterline longitudinal axis of the exterior tubular body and whereinthe central passage of the interior tubular body expands along a lengththereof from a smallest cross-sectional area adjacent a first endportion of the exterior tubular body to a largest cross-sectional areaadjacent a second end portion of the exterior tubular body; and aplurality of helix vanes each extending between an interior surface ofthe exterior tubular body and an exterior surface of the interiortubular body thereby defining a plurality of helical passages betweenthe exterior tubular body, the interior tubular body and respectiveadjacent ones of the helix vanes, wherein each helical passage has aninlet adjacent to the upstream end portion of the exterior tubular bodyand an outlet at a terminal end thereof adjacent to the downstream endportion of the exterior tubular body, wherein the cross-sectional areaof the outlet of each helical passage is bound by a respective portionof the exterior tubular body, a respective portion of the interiortubular body and the respective adjacent ones of the helix vanes tothereby allow material flow through the outlet of the helical passage tomerge with material flow from the outlet of the interior tubular bodyand wherein each of the helical passages tapers along a respectivelength thereof from a largest cross-sectional area adjacent the firstend portion of the exterior tubular body to a smallest cross-sectionalarea adjacent the second end portion of the exterior tubular body. 16.The material flow modifier of claim 15 wherein the cross-sectional areaof the central passage of the interior tubular body expands linearlybetween opposing end portions of the interior tubular body.
 17. Thematerial flow modifier of claim 15 wherein: an upstream end face of theexterior tubular body, an upstream end face of each helix vane and anupstream end face of the interior tubular body all lie in a commonplane; and a downstream end face of the exterior tubular body, adownstream end face of each helix vane and a downstream end face of theinterior tubular body all lie in a common plane.
 18. The material flowmodifier of claim 15 wherein: each of the helical passages is partiallydefined by an outer wall; the outer wall of each of the helical passagesis a respective portion of the exterior tubular body; and the outer wallof all of the helical passages is cylindrical and has a uniform wallthickness along a length thereof.
 19. The material flow modifier ofclaim 15 wherein: each of the helical passages is partially defined byan inner wall; the inner wall of each of the helical passages is arespective portion of the interior tubular body; and the inner wall ofall of the helical passages has a uniform wall thickness along a lengththereof.
 20. The material flow modifier of claim 19 wherein thecross-sectional area of the central passage of the interior tubular bodyexpands linearly between opposing end portions of the interior tubularbody.
 21. The material flow modifier of claim 20 wherein: each of thehelical passages is partially defined by an outer wall; the outer wallof each of the helical passages is a respective portion of the exteriortubular body; and the outer wall of all of the helical passages iscylindrical and has a uniform wall thickness along a length thereof. 22.The material flow modifier of claim 21 wherein: an upstream end face ofthe exterior tubular body, an upstream end face of each helix vane andan upstream end face of the interior tubular body all lie in a commonplane; and a downstream end face of the exterior tubular body, adownstream end face of each helix vane and a downstream end face of theinterior tubular body all lie in a common plane.
 23. A material flowmodifying apparatus, comprising: an inlet flow body having a centralpassage; a material flow modifier having a first end portion thereofattached to the inlet flow body, wherein the material flow modifiercomprises an interior tubular body and a plurality of helical passagebodies surrounding and extending along a length of the interior tubularbody, wherein the interior tubular body has an interior surface and anexterior surface, wherein the interior surface defines a central passageof the interior tubular body, wherein the central passage of theinterior tubular body has a generally round cross-sectional shape andexpands along a length thereof from a smallest cross-sectional areaadjacent an inlet of the interior tubular body to a largestcross-sectional area adjacent an outlet of the interior tubular body,wherein each of the helical passage bodies has opposing side walls, anouter wall and an inner wall jointly defining a helical passagetherebetween, wherein each of the helical passages extend along a lengthof the respective one of the helical passage bodies, wherein the helicalpassage of each of the helical passage bodies has an inlet adjacent tothe inlet of the interior tubular body and an outlet at a terminal endthereof adjacent to the outlet of the interior tubular body, wherein thecross-sectional area of the outlet of each helical passage is bound bythe opposing side walls thereof, the outer wall thereof and the innerwall thereof to thereby allow material flow through the outlet of thehelical passage to merge with material flow from the outlet of theinterior tubular body and wherein each helical passage tapers along arespective length thereof from a largest cross-sectional area adjacentthe inlet thereof to a smallest cross-sectional area adjacent the outletthereof; and an outlet flow body attached to a second end portion of thematerial flow modifier and having a central passage, wherein the outletof the interior tubular body and the outlet of each of the helicalpassages are in fluid communication with the central passage of theoutlet flow body.
 24. The material flow modifying apparatus of claim 23wherein: the inlet flow body, the interior tubular body and the outletflow body each have a central passage defining a respective centerlinelongitudinal axis; and each of said centerline longitudinal axes extendscolinear with each other one of said centerline longitudinal axes. 25.The material flow modifying apparatus of claim 23 wherein: the inletflow body and the outlet flow body each have an upstream end portion anda downstream end portion; the first end portion of the material flowmodifier is attached to the downstream end portion of inlet flow body;the second end portion of the material flow modifier is attached to theupstream end portion of outlet flow body; a cross-sectional area of thecentral passage in the downstream portion of the inlet flow body isgreater than a cross-sectional area of the central passage in theupstream portion of the inlet flow body; and a cross-sectional area ofthe central passage in the upstream portion of the outlet flow body isgreater than a cross-sectional area of the central passage in thedownstream portion of the outlet flow body.
 26. The material flowmodifying apparatus of claim 25 wherein: the inlet flow body, theinterior tubular body and the outlet flow body each have a centerlinelongitudinal axis; and each of said centerline longitudinal axes extendscolinear with each other one of said centerline longitudinal axes. 27.The material flow modifying apparatus of claim 23 wherein thecross-sectional area of the central passage of the interior tubular bodyexpands linearly along the length thereof between the inlet and outletsof the interior tubular body.
 28. The material flow modifying apparatusof claim 23 wherein: an upstream end face of each of the helical passagebodies and an upstream end face of the interior tubular body all lie ina common plane; and a downstream end face of each of the helical passagebodies and a downstream end face of the interior tubular body all lie ina common plane.
 29. The material flow modifying apparatus of claim 23wherein: the outer wall of each of the helical passage bodies iscylindrical; said cylindrical outer wall of all of the helical passagebodies have a uniform wall thickness along a length thereof; and acenterline longitudinal axis of the central passage of the interiortubular body extends colinearly with a centerline longitudinal axis ofsaid cylindrical outer wall of all of the helical passage bodies. 30.The material flow modifying apparatus of claim 23 wherein: the innerwall of each of the helical passage bodies is a respective portion of awall defining the interior tubular body; and each of said opposing wallsis a helix vane.